Thin strip component, method for manufacturing same, and motor using thin strip component

ABSTRACT

A method for manufacturing a thin strip component, including a processing step of processing an amorphous thin strip member into a dimension shape larger than a target shape, and a heat treating step of heat treating and contracting the amorphous thin strip member processed in the processing step to form the amorphous thin strip member into a thin strip component of the target shape. A thin strip component which is a magnetic laminate in which a plurality of plate-shaped thin strip component members of the same shape are laminated, and has a recess over an entire side surface of the magnetic laminate is used. A motor including the thin strip component, a plurality of coils disposed on the thin strip component, and a rotor disposed between the plurality of coils is used.

CROSS-REFERENCE OF RELATED APPLICATIONS

This application is a Divisional application of U.S. patent applicationSer. No. 16/268,455, filed on Feb. 5, 2019, which is a Continuation ofInternational Patent Application No. PCT/JP2018/001498, filed on Jan.19, 2018, which in turn claims the benefit of Japanese Application No.2017-025234, filed on Feb. 14, 2017, the entire disclosures of whichApplications are incorporated by reference herein.

TECHNICAL FIELD

The technical field relates to a thin strip component, a method formanufacturing the same, and a motor using the thin strip component. Inparticular, the technical field relates to a thin strip componentobtained by heat treating a soft magnetic thin strip, a method formanufacturing the same, and a motor using the same.

BACKGROUND

As a laminate of magnetic plates of an iron core (stator) for a motor inthe related art, pure iron or an electromagnetic steel plate is used. Inmotors aimed for higher efficiency, amorphous thin strips or thin stripshaving nanocrystal grains are used in some iron cores (for example, seeJapanese Patent Unexamined Publication No. 6-145917).

A stator core used in this motor is, first, an amorphous alloy thinstrip produced by a liquid quenching method such as a single roll methodor a twin roll method is processed into a predetermined shape by amethod such as winding, cutting, punching, and etching. Next, in orderto improve the magnetic characteristics of the alloy thin strip, theamorphous alloy thin strip is heat treated and crystallized to obtain analloy thin strip having nanocrystal grains. Next, these are laminated toform a stator core, and used for a motor.

SUMMARY

However, in the motor disclosed in Japanese Patent UnexaminedPublication No. 6-145917, since the amorphous alloy thin strip isprocessed into a predetermined shape and heat treated, the distancebetween atoms constituting the thin strip is narrowed as the temperaturerises, and contraction of the thin strip occurs.

As a result, the shape of the stator core after the heat treatmentsometimes does not fall within a predetermined range. Therefore,troubles have occurred in assembling the stator to the motor. A gapdistance between the stator core and a rotor core was not constant, andthe motor characteristics were not constant.

Therefore, an object of the disclosure is to provide a thin stripcomponent excellent in shape accuracy and magnetic characteristics evenif the contraction occurs in the thin strip component by heat treatment,a method for manufacturing the same, and a motor using the thin stripcomponent.

In order to achieve the above-described object, a method formanufacturing a thin strip component including a processing step ofprocessing an amorphous thin strip member into a dimension shape largerthan a target shape, and a heat treating step of heat treating andcontracting the amorphous thin strip member processed in the processingstep to form the amorphous thin strip member into a thin strip componentof the target shape is used.

A method for manufacturing a thin strip component including a processingstep of processing an amorphous thin strip into a dimension shape largerthan a target shape, a laminating step of laminating the amorphous thinstrips processed in the processing step, and a heat treating step ofheat treating and contracting a laminate of the amorphous thin stripsafter the laminating step to form the amorphous thin strips into alaminated thin strip member of the target shape is used.

A thin strip component which is a magnetic laminate in which a pluralityof plate-shaped thin strip component members of the same shape arelaminated, and has a recess over an entire side surface of the magneticlaminate is used.

A thin strip component which is a magnetic laminate in which a pluralityof plate-shaped thin strip component members of the same shape arelaminated, and to which the thin strip components are bonded is used.

A thin strip component which is a magnetic laminate in which a pluralityof plate-shaped thin strip component members of the same shape arelaminated, in which one plane is formed by covering a side surface ofthe magnetic laminate with resin is used.

A thin strip component which is a magnetic laminate in which a pluralityof plate-shaped thin strip component members of the same shape arelaminated, in which one plane is formed on a side surface of themagnetic laminate, and resin is positioned between the thin stripcomponents is used.

A motor including the above-described thin strip component, a pluralityof coils disposed on the thin strip component, and a rotor disposedbetween the plurality of coils is used.

As described above, according to the thin strip component, the laminate,the method for manufacturing thereof, and the motor of the disclosure,it is possible to improve the shape accuracy and the magneticcharacteristics of the thin strip component, and the motorcharacteristics.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of an iron thin strip component in an amorphousstate according to Embodiment 1 of the disclosure;

FIG. 2A is a side view of a laminate in which heat treated thin stripcomponents are laminated according to Embodiment 1 of the disclosure;

FIG. 2B is a top view of the laminate in which the heat treated thinstrip components are laminated according to Embodiment 1 of thedisclosure;

FIG. 3A is aside view of a motor using the laminate according toEmbodiment 1 of the disclosure;

FIG. 3B is a top view of the motor using the laminate according toEmbodiment 1 of the disclosure;

FIG. 4A is a cross-sectional view of a vicinity of end surface of teethof the laminate according to Embodiment 1 of the disclosure;

FIG. 4B is a front view of the teeth of the laminate according toEmbodiment 1 of the disclosure;

FIG. 5 is a cross-sectional view of a vicinity of an end surface of alaminate according to Embodiment 2 of the disclosure;

FIG. 6A is a cross-sectional view of a vicinity of an end surface of alaminate according to Embodiment 3 of the disclosure;

FIG. 6B is a front view of the vicinity of the end surface of thelaminate according to Embodiment 3 of the disclosure;

FIG. 7 is a view showing a cross-sectional configuration of a heattreatment device for a laminate according to Embodiment 4 of thedisclosure;

FIG. 8A is a cross-sectional view of a vicinity of an end surface of thelaminate according to Embodiment 4 of the disclosure;

FIG. 8B is a front view of the vicinity of the end surface of thelaminate according to Embodiment 4 of the disclosure;

FIG. 9A is a cross-sectional view of a vicinity of an end surface of alaminate according to Embodiment 5 of the disclosure;

and

FIG. 9B is a front view of the vicinity of the end surface of thelaminate according Embodiment 5 of the to disclosure.

DESCRIPTION OF EMBODIMENTS

Hereinafter, embodiments of the disclosure will be described withreference to the drawings.

Embodiment 1

FIG. 1 is a plan view of amorphous thin strip member 1 according toEmbodiment 1 of the disclosure.

Amorphous Thin Strip Member 1

Amorphous thin strip member 1 is an iron thin strip component, amagnetic member.

Amorphous thin strip member 1 has a plurality of T-shaped portionscalled teeth 1 a on an inner side. In a case where amorphous thin stripmember 1 is used for a motor, rotor 10 is placed on the inner side ofend surface 30 of teeth 1 a. Finally, coils are wound on these teeth la.A current flows through the coils, a magnetic field is generated, rotor10 rotates, and becomes a motor.

There are fitting holes 1 b at four positions around amorphous thinstrip member 1. A fixing member such as a bolt is inserted into eachfitting hole 1 b.

There is donut-like or hollow frame-shaped core back 1 c which connectsa plurality of teeth 1 a and has the fitting holes 1 b on an outerperiphery of amorphous thin strip member 1.

Heat Treatment

Amorphous thin strip member 1 is heat treated to improve magneticcharacteristics. In particular, when fine crystal grains of pure ironcalled nanocrystal grains are generated by being crystallized in theheat treatment, soft magnetic characteristics are improved. Amorphousthin strip member 1 is a magnetic material, the coils are wound, andbecomes a component of the motor.

Since amorphous thin strip member 1 is in an unstable state in which theinteratomic distance is longer than the unique interatomic distance,atoms move so that the interatomic distances become unique distances forstabilization as the temperature rises due to the heat treatment . As aresult, amorphous thin strip member 1 contracts. Since the heat treatedthin strip becomes brittle, at the time of manufacturing, it isnecessary to perform a shaping process in the amorphous state, and thenmove onto the heat treating step.

Process

In Embodiment 1, a method for manufacturing a thin strip componentincluding a processing step of processing amorphous thin strip member 1into a predetermined shape having a ratio of a dimension larger than atarget shape, and a heat treating step of heat treating and contractingprocessed amorphous thin strip member 1 into a shape within a targetdimension is used.

That is, amorphous thin strip member 1 is processed to a large dimensionin consideration of the contraction factor of amorphous thin stripmember 1 due to the heat treatment . Amorphous thin strip member 1processed to be larger is heat treated, contracted, and contained withinthe predetermined dimensional specification. In amorphous thin stripmember 1, the movement of atoms becomes clear from about 100° C., andnanocrystal grains having a size of several tens of nanometers begin tobe generated between about 370° C. to 500° C.

It takes several seconds or more for the treatment time to improve themagnetic characteristics, so the lower the temperature the longer ittakes. The contraction factor is 0.6% at maximum in the uniaxialdirection for a rectangular test piece, but the value varies dependingon the heat treatment conditions. As the temperature of the heattreatment is higher or the heat treatment is longer, the movement amountof the atoms becomes larger, so that the contraction factor becomeslarger.

The processing dimension is decided accordingly. Regarding thecontraction factor, the influence of plate thickness is small. On theother hand, regarding the contraction factor, the influence of the shapeis large, and the behavior of the contraction factor depending on thelocation is complicated depending on the shape. Since not only thecontraction factor of each material itself but also the manner ofconnection of the materials are mutually restrained, the contractionfactor is not uniform and varies from place to place.

It is the T-shaped portion that is teeth 1 a which needs to consider thecontraction factor in order to improve the shape accuracy. A rotor,which is rotor 10, is inserted into the inner diameter portion.Therefore, when a gap between rotor 10 and end surface 30 of teeth 1 ais large, the motor efficiency is deteriorated, and when the gap is notconstant, the rotation operation becomes unstable.

End surface 30 of a tip portion of teeth 1 a shows the most complicatedcontraction behavior. If the shape accuracy of teeth 1 a is poor, themotor characteristics also become unstable.

There are fitting holes 1 b at four positions around amorphous thinstrip member 1. The position of each fitting hole 1 b is importantbecause it affects the positional accuracy of the center of amorphousthin strip member 1 and the accuracy of a diameter of a space into whichrotor 10 is inserted.

There is donut-like or hollow frame-shaped core back 1 c which connectsthe plurality of teeth 1 a and has fitting hole 1 b. The accuracy ofcore back 1 c may be lower than that of teeth 1 a or fitting hole 1 b interms of the degree of rigidity. Process

Therefore, a shape close to the final shape is produced first, and heattreated. The ones subjected to heat treatment are measured and thecontraction factor is determined. The contraction factor measured withdifferent heat treatment conditions and the portion shape is between 0%to 0.6%. The contraction amount after the heat treatment is influencedby the nonuniformity such as the amorphous state in amorphous thin stripmember 1, the plate thickness, the temperature during the heattreatment, and the like. There is a difference in the contraction amounteven if the same treatment is carried out. However, if the maximumdiameter is about 130 mm or less as in this embodiment, the accuracy iswithin ±0.01 mm. Laminate

FIG. 2A is a side view of thin strip component 3 in which thin stripcomponent members 2 obtained by heat treating amorphous thin stripmember 1 are laminated. FIG. 2B is a top view of thin strip component 3in which thin strip component members 2 obtained by heat treatingamorphous thin strip member 1 are laminated. In laminated thin stripcomponent 3, heat treated thin strip component members 2 are laminatedand fastened by nut 7 via spring washer 5 and washer 6 by bolt 4. Here,the fixation is four positions.

After laminating a plurality of or more amorphous thin strip members 1,amorphous thin strip members 1 may be heat treated and fastened by bolt4 as shown in FIG. 2A to form laminated thin strip component 3.

Laminated thin strip component 3 is a magnetic laminate in which aplurality of plate-shaped thin strip component members 2 of the sameshape are laminated.

Motor

FIG. 3A is a side view of a motor using laminated thin strip component3, and FIG. 3B is a top view of the motor using laminated thin stripcomponent 3. In laminated thin strip component 3 of FIGS. . 2A and 2B,nut 7 is removed at one end, metal base 8 is inserted under laminatedthin strip component 3 and fastened again by nut 7.

Next, winding 9 is applied to laminated thin strip component 3 at aportion called teeth 1 a (FIG. 1) of thin strip component member 2 tomake it a stator. Rotor 10 is installed in the inner diameter portion oflaminated thin strip component 3. If electricity is supplied to winding9 in this state, it can be driven as a motor.

Teeth 1 a

FIG. 4A is a cross-sectional view of a vicinity of end surface 30 ofteeth 1 a of laminated thin strip component 3, and FIG. 4B is a frontview of a vicinity of end surface 30 of teeth 1 a of laminated thinstrip component 3.

As described in FIG. 1, the dimensional accuracy of thin strip componentmember 2 after heat treatment is within ±0.01 mm. In addition,misalignment in the plane tends to occur during the lamination. Even ifthe accuracy of the alignment is increased, unevenness occurs on endsurface 30 due to the deviation of the dimensions caused by the heattreatment.

Dimensional variations a of the unevenness of FIG. 4A and dimensionalvariation of end surface 30 in dimensional variation b of the unevennessof FIG. 4B are both within ±0.1 mm. Since thin strip component member 2is heat treated, it is possible to confirm visible oxide film 11 on endsurface 30 in FIG. 4B. Oxidation does not progress and corrosionresistance improves due to the presence of oxide film 11.

Embodiment 2

FIG. 5 is a cross-sectional view of a vicinity of end surface 30 ofteeth 1 a of laminated thin strip component 3 according to Embodiment 2of the disclosure. Items not described are the same as those inEmbodiment 1.

FIG. 5 is different from FIG. 4 in Embodiment 1 in that resin coatinglayer 12 is formed on end surface 30 of thin strip component members 2.Unevenness occurs on end surface 30 due to the difference in contractionamount of each thin strip component member 2. However, it isparticularly important to improve the accuracy of mutual gap distance(distance between end surface 30 and rotor 10) in the inner diameterportion in which rotor 10 is rotated.

In order to solve the dimensional difference, resin coating layer 12 isformed on end surface 30. When resin coating layer 12 enters deeper intothe interlayer of thin strip component members 2, the space factorbecomes worse. Therefore, resin coating layer 12 is formed only on endsurface 30 mainly. Since end surface 30 has unevenness, even if resincoating layer 12 is formed only in the vicinity of the surface of endsurface 30, the bonding force can be sufficiently secured. Furthermore,if the surface of resin coating layer 12 is cut to form plane 31, theshape accuracy is further improved.

It is preferable to form resin coating layer 12 only on teeth 1 aportion of thin strip component 3.

Embodiment 3

FIG. 6A is a cross-sectional view of a vicinity of end surface 30 ofteeth 1 a of laminated thin strip component 3 according to Embodiment 3of the disclosure. FIG. 6B is a front view of the vicinity of endsurface 30 of teeth 1 a of laminated thin strip component 3 according toEmbodiment 3 of the disclosure. Items not described are the same asthose in Embodiments 1 and 2.

FIG. 6A is different from FIG. 5 in Embodiment 2 in that the surface ofresin coating layer 12 is cut to expose thin strip component members 2from end surface 30 to form one plane 31. Although thin strip componentmembers 2 can be brittle due to the heat treatment, by leaving a statein which the interlayer is bonded by resin coating layer 12 in endsurface 30, it is possible to perform cutting without damaging thinstrip component members 2.

By the cutting process, the unevenness amount of the cross sectiondecreases, and cutting trace 13 having metallic luster remains as seenfrom the front.

This not only improves the accuracy of the gap distance between rotor 10and end surface 30 in particular, but also makes it possible to reducethe gap distance with thin strip component members 2. As a result, themotor efficiency is further improved.

It is preferable to perform the above-described treatment only on teeth1 a portion of thin strip component 3.

Embodiment 4

FIG. 7 is a view showing a cross-sectional configuration of a heattreatment device of laminated thin strip component 3 according toEmbodiment 4 of the disclosure. Items not described are the same asthose in Embodiments 1 to 3.

Laminate 14 of amorphous thin strip members 1 is sandwiched betweenpressure plates 15, and heated by heater 16 in pressure plate 15 so asto perform heat treatment while pressing. During the heat treatmentprocess, the surface of oxide film 32 develops between amorphous thinstrip members 1, and the entire or a portion of the members are mutuallybonded to each other. As a result, since laminate 14 is integrated, thehandling after heat treatment becomes easier.

Oxide film 32 is larger on the outside of laminate 14 than betweeninside amorphous thin strip member 1.

FIG. 8A is a cross-sectional view of a vicinity of end surface 30 oflaminate 17 after the heat treatment, and FIG. 8B is a front view of thevicinity of end surface 30 of laminate 17 after the heat treatment. Whenthe heat treatment is performed while pressing laminate 14 the above andbelow, there is frictional resistance against contraction at theboundary between pressure plate 15 and laminate 14.

Under the heat treatment conditions under which nanocrystal grains aregenerated, amorphous thin strip member 1 itself generates heat and theheat is accumulated on the central side of laminate 14, so that thetemperature rises, and the contraction factor on the central side alsoincreases. Due to these influences, the contraction amount in the centerbecomes large and recess 18 exists sometimes on end surface 30 oflaminate 17 after heat treatment.

In the motor shown in FIGS. 3A and 3B, operation failure occurs when endsurface 30 and rotor 10 come into contact with each other. Therefore, asshown in FIG. 8A, if the shape has recess 18, thin strip componentmembers 2 at both upper and lower ends of laminate 17 serve as areference, and the shape is regulated. As a result, there is anadvantage that the accuracy can be easily secured.

Laminate 14 is a magnetic laminate in which the plurality ofplate-shaped thin strip components 2 of the same shape are laminated,and is a thin strip component having recess 18 over the entire sidesurface of the magnetic laminate. As for the size of thin stripcomponent member 2, thin strip component member 2 located outsidelaminate 14 has a larger size.

Embodiment 5

FIG. 9A is a cross-sectional view of a vicinity of end surface 30 ofteeth 1 a of laminate 17 according to Embodiment 5 of the disclosure.FIG. 9B is a front view of the vicinity of end surface 30 of teeth 1 aof laminate 17 according to Embodiment 5 of the disclosure. Items notdescribed are the same as those in Embodiment 4. In Embodiment 5,laminate 17 of Embodiment 4 is further processed to form one plane onthe side surface.

FIGS. 9A and 9B are different from FIGS. 8A and 8B in Embodiment 4 inthat the surface of end surface 30 is cut to form one plane 31. Althoughthin strip component members 2 can be brittle due to the heat treatment,this process is possible because the entire or a portion of theinterlayer of thin strip component members 2 are bonded to each other byoxide film 32 by performing the heat treatment while pressing in thedevice of FIG. 7.

Accordingly, thin strip component members 2 in the vicinity of endsurface 30 are fixed and can be cut without being damaged. By thecutting process, the unevenness amount of end surface 30 decreases, andcutting trace 13 having metallic luster remains as seen from the front.Cutting trace 13 is a line-shaped unevenness. Accordingly, the accuracyof the gap distance between rotor 10 and end surface 30 is particularlyimproved, so that the motor efficiency is improved.

As a Whole

The above-described embodiments can be combined. For example,Embodiments 2 and 3 maybe applied to the laminate produced inEmbodiments 4 and 5.

Although teeth 1 a have been mainly described, it can be similarlyapplied to other parts of thin strip component members 2.

The thin strip component is an example and can be applied to otherstructures and shapes.

According to the thin strip component, the laminate, the method formanufacturing thereof, and the motor of the disclosure, it is possibleto improve the shape accuracy and the magnetic characteristics of thinstrip component, and the motor characteristics. Furthermore, thelaminate according to the disclosure can also be applied to applicationsof electronic components such as transformers, other than motors.

REFERENCE SIGNS LIST

-   1 AMORPHOUS THIN STRIP MEMBER-   1 a TEETH-   1 b FITTING HOLE-   1 c CORE BACK-   2 THIN STRIP COMPONENT MEMBER-   3 THIN STRIP COMPONENT-   4 BOLT-   5 SPRING WASHER-   6 WASHER-   7 NUT-   8 METAL BASE-   9 WINDING-   a DIMENSIONAL VARIATION-   b DIMENSIONAL VARIATION-   10 ROTOR-   11 OXIDE FILM-   12 RESIN COATING LAYER-   13 CUTTING TRACE-   14 LAMINATE-   15 PRESSURE PLATE-   16 HEATER-   17 LAMINATE-   18 RECESS-   30 END SURFACE-   31 PLANE

What is claimed is:
 1. A method for manufacturing a thin stripcomponent, comprising: a processing step of processing an amorphous thinstrip member into a dimension shape larger than a target shape; and aheat treating step of heat treating and contracting the amorphous thinstrip member processed in the processing step to form the amorphous thinstrip member into a thin strip component member of the target shape. 2.The method for manufacturing a thin strip component of claim 1, furthercomprising: a laminating step of laminating a plurality of the thinstrip component members after the heat treating step.
 3. A method formanufacturing a thin strip component of claim 1, comprising: aprocessing step of processing an amorphous thin strip into a dimensionshape larger than a target shape; a laminating step of laminating theamorphous thin strips processed in the processing step; and a heattreating step of heat treating and contracting a laminate of theamorphous thin strips after the laminating step to form the amorphousthin strips into a laminated thin strip component members of the targetshape.
 4. The method for manufacturing a thin strip component of claim3, wherein, in the heat treating step, the heat treatment is performedwhile pressing the laminated amorphous thin strip in a laminationdirection.
 5. The method for manufacturing a thin strip component ofclaim 3, wherein, in the heat treating step, the laminated thin stripcomponent members are bonded to each other.
 6. The method formanufacturing a thin strip component of claim 3, wherein, in the heattreating step, a side surface of the laminated thin strip componentmembers is recessed.
 7. The method for manufacturing a thin stripcomponent of claim 1, wherein the amorphous thin strip member having adimension larger than the target shape is larger than 0% of the targetshape and 0.6% or less than the target shape.
 8. The method formanufacturing a thin strip component of claim 1, wherein the processingof the amorphous thin strip into the dimension shape larger than thetarget shape further includes the dimension shape depending on alocation of the amorphous thin strip member.
 9. The method formanufacturing a thin strip component of claim 1, wherein the processingof the amorphous thin strip into the dimension shape larger than thetarget shape further includes the dimension shape depending on acondition of the heat treating step.
 10. The method for manufacturing athin strip component of claim 9, wherein the amorphous thin strip memberhaving a dimension larger than the target shape is increased indimension as a temperature in the heat treating step is higher or a timein the heat treating step is longer.